|Publication number||US8043065 B2|
|Application number||US 12/434,197|
|Publication date||Oct 25, 2011|
|Filing date||May 1, 2009|
|Priority date||May 1, 2009|
|Also published as||CN101876293A, CN101876293B, EP2246558A2, EP2246558A3, EP2246558B1, US20100278654|
|Publication number||12434197, 434197, US 8043065 B2, US 8043065B2, US-B2-8043065, US8043065 B2, US8043065B2|
|Inventors||Steven Alan Kyriakides|
|Original Assignee||General Electric Company|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (20), Referenced by (9), Classifications (14), Legal Events (2)|
|External Links: USPTO, USPTO Assignment, Espacenet|
The present invention relates generally to wind turbine rotor blades, and more particularly to a wind turbine rotor blade having one or more prefabricated leading edge components
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one more rotor blades. The rotor blades capture kinetic energy from wind using known foil principles, and transmit the kinetic energy through rotational energy to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
The construction of a modern wind turbine rotor blade generally includes upper and lower shell components bonded at a leading and trailing edge of the blade, spar caps, and one or more shear webs. The skin, typically manufactured from layers of fiber composite and a lightweight core material, forms the exterior aerodynamic foil shape of the rotor blade. The spar caps provide increased rotor blade strength by integrating one or more structural elements running along the length of the rotor blade on both interior sides of the rotor blade. Shear webs are structural beam-like components running essentially perpendicular between the top and bottom spar caps and extending across the interior portion of the rotor blade between the outer skins. Spar caps have typically been constructed from glass fiber reinforced composites, though some larger blades are beginning to include spar caps constructed from carbon fiber reinforced composites.
With conventional constructions, the leading edge of the wind turbine blade is an area of concern. The bonding of the shell components at the leading edge is difficult to control. Overbite or underbite between the shell components can occur, often causing extensive rework of the blade. The thickness of the bond can vary from blade to blade, and can often drift outside of a design tolerance. The leading edge bond between the shell components can result in a blade where the most dimensional uncertainty is at a very critical aerodynamic location on the blade. In addition, the leading edge of the turbine blade is highly susceptible to erosion and weathering, and can be damaged during transportation and erection of the wind turbine. These conditions lead to costly on-site repairs.
Accordingly, there is a need for a wind turbine rotor blade design that addresses at lest certain of the present disadvantages associated with blades having shell components bonded together at the leading edge of the blade.
The present invention provides for a wind turbine rotor blade that incorporates one or more prefabricated leading edge segments. These segments can be manufactured with precisely controlled geometries, and do not include a leading edge bond. The blades provide a solution to several of the problems associated with conventional blades having shell components bonded together at the leading edge of the blade. Additional aspects and advantages of the invention are set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
A wind turbine rotor blade is provided having a first shell component and a second shell component. The shell components are joined together at the trailing edge of the blade. Each of the shell components further includes a forward edge. At least one, and in a particular embodiment, a plurality of leading edge segments are joined to the shell components and aligned along the longitudinal length of the blade so as to define a continuous leading edge of the blade. The leading edge segments have an open-ended cross-sectional profile defined by an arcuate skin with first and second longitudinal edges and first and second end faces. The longitudinal edges of the leading edge segments are joined to the forward edge of the first shell component at a first bond line, and joined to the forward edge of the second shell component at a second bond line. The end faces of adjacent leading edge segments may be bonded together as well. With this construction, the leading edge portion of the blade between the first and second bond lines is a continuous unbroken surface defined by the aligned leading edge segments.
The present invention also encompasses a kit for forming a wind turbine rotor blade from component parts. The kit may include a first shell component and a second shell component, with each of the shell components having a forward edge and a trailing edge. One or more leading edge segments are also provided, with each leading edge segment having an open-ended cross-sectional profile defined by an arcuate skin with first and second longitudinal edges and first and second end faces. The leading edge segments and the first and second shell components are configured relative to each other such that when assembled, the shell components define a bonded trailing edge of the blade, and the longitudinal edges of the leading edge segments are joined to the forward edge of the first shell component at a first bond line, and joined to the forward edge of the second shell component at a second bond line. With this kit configuration, when assembled, the parts define a blade with a leading edge that is a continuous unbroken surface defined by the skins of the aligned leading edge segments between the first and second bond lines.
It should be readily appreciated, that the other attributes and characteristics of the various embodiments described herein relate to the individual components of the kit embodiments as well.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
The leading edge segments 34 may complete the blade 10 from the tip 12 to the root 14 of the blade 10. In an alternative embodiment, fewer leading edge segments may be utilized, wherein a portion of the blade leading edge 32 is defined by the shell components 18, 24, or other structure. The leading edge segment 34 closest to the root 14 may also attach directly to a root ring 16, or other structure of the blade 10. Likewise, the leading edge segment 34 closest to the tip 12 may attach to a tip component, which may be a section of the shell components 18, 24, or a separate tip structure. When completed the blade 10 as depicted in
The leading edge segments 34 may be prefabricated from a single piece of skin or shell material 36. For example, the skin 36 may be molded as a single integral piece, and may be made from the same material as the shell components 18, 24. The prefabricated leading edge components 34 may be formed from a thermoplastic or thermoset material, as well as a glass, carbon, or particle-reinforced composite material. In addition, the leading edge segments 34 may be formed from a material or treated with a coating or other application to provide the leading edge of the blade 10 with certain desired characteristics as compared to the shell components 18, 24. For example, the leading edge segments may be formed of a material that does not require painting, and which may include a UV resistant material or coating, or other material or coating that enhances weathering and erosion resistance. The leading edge segments 34 may have a different color or other visual characteristic as compared to the shell components 18, 24. It should be readily appreciated that the construction and materials for the leading edge segments 34 are not a limitation of the present invention.
With particular embodiments, it may be desired that the end faces 42, 43 of adjacent leading edge segments 34 are also bonded or otherwise joined together along the length of the blade 10. The end faces 42, 43 may include any manner of splice or joint configuration, such as a dove-tail joint or lap-splice configuration, to ensure positive interlocking engagement between the respective adjacent end faces.
It should also be appreciated that any manner of conventional joint configuration, such as a dove-tail joint or lap-splice configuration, may also be included between the longitudinal edges 38, 40 of the leading edge segments 34 and the forward edges 20, 26 of the respective shell components 18, 24, or between the end faces of the most proximal and most distal edge components (or the end faces of the single edge component embodiment of
In a particularly unique embodiment, the bracing webs 54 may be formed from an electrically non-conductive material, and include one or more conductive strip members 56 may run longitudinally within the leading edge segment 34. These conductive strip members 56 may join to the conductive strip members 56 of adjacent leading edge segments 34 by way of any manner of conventional connector 58 so as to define a continuous conductive arrangement for all of the leading edge segments 34, as depicted in
It should be appreciated that the present invention also encompasses a kit for forming a wind turbine rotor blade 10 as depicted in
While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
|Cited Patent||Filing date||Publication date||Applicant||Title|
|US4118147 *||Dec 22, 1976||Oct 3, 1978||General Electric Company||Composite reinforcement of metallic airfoils|
|US5314309 *||Dec 10, 1991||May 24, 1994||Anthony Blakeley||Turbine blade with metallic attachment and method of making the same|
|US5782607||Dec 11, 1996||Jul 21, 1998||United Technologies Corporation||Replaceable ceramic blade insert|
|US6457943||Sep 9, 1999||Oct 1, 2002||Im Glasfiber A/S||Lightning protection for wind turbine blade|
|US6508000 *||Feb 8, 2001||Jan 21, 2003||Siemens Westinghouse Power Corporation||Transient liquid phase bonding repair for advanced turbine blades and vanes|
|US6612810||Jun 20, 2000||Sep 2, 2003||Lm Glasfiber A/S||Wind turbine blade with a system for deicing and lightning protection|
|US7040864||Apr 9, 2001||May 9, 2006||Jomitek Aps||Lightning protection system for a construction, method of creating a lightning protection system and use thereof|
|US7351040||Jan 9, 2006||Apr 1, 2008||General Electric Company||Methods of making wind turbine rotor blades|
|US7618712 *||Nov 8, 2005||Nov 17, 2009||Siemens Energy, Inc.||Apparatus and method of detecting wear in an abradable coating system|
|US20020148115 *||Feb 8, 2001||Oct 17, 2002||Siemens Westinghouse Power Corporation||Transient liquid phase bonding repair for advanced turbine blades and vanes|
|US20030129061 *||Jan 8, 2002||Jul 10, 2003||General Electric Company||Multi-component hybrid turbine blade|
|US20040253114||Jul 19, 2002||Dec 16, 2004||Ole Gunneskov||Wind turbine blade|
|US20080145229 *||Dec 15, 2005||Jun 19, 2008||Jose Ignacio Llorente Gonzalez||Lightning Arrester System for a Wind Generator Blade|
|US20080159870||Jun 13, 2007||Jul 3, 2008||Hontek Corporation||Method and coating for protecting and repairing an airfoil surface using molded boots, sheet or tape|
|US20080206062 *||Feb 25, 2008||Aug 28, 2008||Gamesa Innovation & Technology, Sl.||Wind turbine multi-panel blade|
|US20090196751 *||Feb 1, 2008||Aug 6, 2009||General Electric Company||Wind turbine blade with lightning receptor|
|US20110058934 *||Sep 8, 2009||Mar 10, 2011||James Allister W||Cooled Turbine Airfoil Fabricated From Sheet Material|
|WO1996002417A2||Jun 21, 1995||Feb 1, 1996||United Technologies Corp||Apparatus and methods for fabricating a helicopter main rotor blade|
|WO1998046418A1||Mar 25, 1998||Oct 22, 1998||Sikorsky Aircraft Corp||Apparatus and method for installing a leading-edge sheath onto a helicopter main rotor blade subassembly|
|WO2001046582A2||Dec 19, 2000||Jun 28, 2001||Aerodyn Eng Gmbh||Rotor blade for wind power installations|
|Citing Patent||Filing date||Publication date||Applicant||Title|
|US8382440||Jun 6, 2011||Feb 26, 2013||Modular Wind Energy, Inc.||Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use|
|US8425196 *||Jan 28, 2011||Apr 23, 2013||General Electric Company||Wind turbine blades with a hardened substrate construction|
|US8459955 *||Jun 11, 2013||Rolls-Royce Plc||Aerofoil|
|US8556590 *||Dec 25, 2009||Oct 15, 2013||Mitsubishi Heavy Industries, Ltd.||Wind-turbine rotor blade|
|US20100054945 *||Mar 4, 2010||Rolls-Royce Plc.||Aerofoil|
|US20110006165 *||Jul 8, 2010||Jan 13, 2011||Peter Ireland||Application of conformal sub boundary layer vortex generators to a foil or aero/ hydrodynamic surface|
|US20110243751 *||Oct 6, 2011||General Electric Company||Wind turbine blades with a hardened substrate construction|
|US20120141282 *||Dec 25, 2009||Jun 7, 2012||Mitsubishi Heavy Industries, Ltd.||Wind-turbine rotor blade|
|EP2708740A1||Sep 17, 2012||Mar 19, 2014||Nordex Energy GmbH||Wind energy assembly rotor blade with an electric heating device and a lightening conductor|
|U.S. Classification||416/224, 416/241.00R, 416/230, 416/232, 416/226, 416/223.00R|
|Cooperative Classification||F05B2230/50, F03D1/0675, F05B2230/60, Y02E10/721, F03D11/0033, Y02E10/722|
|May 1, 2009||AS||Assignment|
Owner name: GENERAL ELECTRIC COMPANY, NEW YORK
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KYRIAKIDES, STEVEN ALAN;REEL/FRAME:022627/0621
Effective date: 20090501
|Apr 27, 2015||FPAY||Fee payment|
Year of fee payment: 4